The Below info is taken from my document i've been writing since i started the project ,so with my slow progress this is 2 years of work but i have replaced or upgraded every component with new items , I have loads more pics and step by step write ups but can't really be bothered to post it all.
Also alot of the pictures are poo quality due to my phone
Some of you may know I have now sold all my Bmw M20 turbo equipment and are now in the process of purchasing a post 1993 Saab 9000 aero for the engine. I juct couldn't justify spending 7k on an engine.
PS You don't know how many times iv almost sold every thing a bought something else to abuse.
Before I get into the project I’ll explain the story which leads me to the point I’m at now (and thousand of pounds worse off)
In October 2005 I was at university in Swansea and was in serious need off a run around and craved some sideways action (I currently had a very special VW Polo G40 at home and didn’t want to take it to the car crime capital of Wales). Several of my friends had E30 325i’s and this is what I decided on. Ebay was my next port of call and a 169k 325i SE was purchased
After a few weeks it was clear that the 20 year old E30 could be so much better with an input of cash, however being a broke student I didn’t have any and as a result the G40 was sold to fund the initial project
The spec was planned and purchased
SPAX PSX kit -60
Strip the interior
DS2500 pads and Black diamond disks
Sparco steering wheel
Powerflex bushes through out
6 Point cage.
15” split wheels
I was happy with this for a few months and did a few track days/drifting. However it soon be came clear that the 325i isn’t that quick and is in desperate need of some more power.
I wanted to create an e30 that was as much fun in the dry as the stripped 325i with LSD is in the wet. With little research it was clear that Turboing the M20 was the way to go and while the engine was out the 2 door shell was going to be resprayed (September 2006)
So the engine was taken out and the plan was to respray the shell.
At this point I purchased some goodies with the below spec and said good buy to a student loan
Fully rebuild: rebored block, lead copper big end and main bearings etc
8:1 C:R with JE forged pistons and total seal rings
O-Ringed + decked block by 0.1mm
PPF valves + springs with high accuracy cut valve seat
Welded water jackets (where appropriate)
New valve stems
Standard Cam (possible change before completion)
Spec 3 clutch
However once the strip down started, the shell was past its best and an alternative was found in the shape of a recently resprayed and derusted rolling touring shell.
Saying buy buy to the original
Here is a pic after I got rid of the rusty old running gear, the outside had been sprayed very well in brilliant red, although the interior was still the original alpine white, this didn't bother me as the cage and chassis mods would have damaged the paint anyhow.
The next stage was to start planning a spec list, due the exchange rate at the time I bought a lot of stuff from Ireland engineering in the us.
E30 front coilover conversion kit
Urethane rear Subframe mounts
Urethane engine mounts
Urethane gearbox mounts
Adjustable camber top mounts
Adjustable rear camber and toe kit
Billet rear anti roll bar mounts
Billet rear top mounts
Eibach 550Ibs / 600Ibs coilover spring kitFront strut Conversion
The below pic shows the front struts after sandblasting with the ring welded on for the coilover perch
Here the strut assembly shown once sprayed and assembled with the top mounts Rear Bean Conversion
When ordering the suspension parts the camber and toe adjustment kit was chosen, this will in the future allow the car to be setup as necessary for drift or track use and also give the option of reducing the excessive negative camber produced when lowering the e30.
Outer pick up points are for toe and inner are for camber, hence why the outer bracket slot is horizontal and the inners are vertical.
A dye grinder was used for the slots
The New bushes being installed
Rear beam Finalised with the brackets welde and whole beam paintedFront Subframe Reinforcement
To prevent flex in the front cross member due to big power reinforcement brackets were purchased from UWEM3
Below of subframe after sandblasting
Subframe with bracket welded on.
Subframe paintedShell Work
Now work started on the shell.
First, I wire brushed the underside and waxoyled it.
Following this work started in side, the first step was to remove the nasty/ heavy sound deadening.
This is a horrible job, Ive learnt recently that te easiest method is using dry ice. Not chipping inch by inch with a screw driver and hammer Sunroof removal
To save further weight i decided to remove the sunroof and replace it with a cabon fibre panel.
I had to leave a lip for the panel to be bonded/ riveted to
Once that was tidied up, I used Proflex for the bonding and screwed the carbon panel in place.Rear Diff hanger Modifications
With some research, it became clear that the weakness in the e30 shell when running a large increase in torque/power was the rear differential hanger and after viewing the picture below it was decided that thorough reinforcement was required
While Chatting to Ant @ Atech he gave me a few ideas and i knocked up a drawing on Solidworks,
When sourcing a diff, i contacted Kevo and he built me one to my specification.
E36 back plate and trigger wheel
Sand blasted casing
50% Lockup LSD
At this point the Cage was also welded in
Once the fabrication was complete the inside was sparyed.Inside Respray
The inside was complete degreased and rubber down usin 600 grit sand paper.
Then red oxide primer was applied.
following this that coat was rubbed down using 1200 grip and the brilliant red first coat was applied.
This coat was then rubbed down with 1200 grit and another coat was applied. Following this a clear coat was added.
In the above pic the colour looks a little orange but this is due to my poo camera phone.
With the car sprayed the running gear was bolted onSuspension and driveline spec so far
Here it is the progress to date, still lots to do but most is bolting bits on so progress will be fast.
Coilover fronts with eibach 600ibs springs and spax adjustible dampers
Rear Eibach 650ibs springs and spax adjustible dampers
Adjustible top mounts
Adjustible rear beam with ireland engineering bushes othrough out
M3 control arm bushes
H&R roll bars
Billet rear anti roll bar pick up points
Ireland engineering rear billet top mounts
Ireland engineering Front strut brace
6 Point OMP FIA roll cage
Z3 1.9 steering rack
Solid Steering Guibo
Every bolt /bracket /bush replaced
Wilwood 310mm brakes
25 mm master cylinder
50% lock up and rebuilt LSD
E36 diff back plate
Modified diff hanger and reinforced rear end
BBS LM replicas (wanted the real ones but cound't spend 2k on wheels
Toyo T1r tyres
Ive also installed my Fuel cell today, helps with space around the rear beam when changing setup and hepls with the front heavy e30.
IMO it also looks ace.
Heres the pic of the recently installed front intercooler the front was cut away for this to be installed.
Some other Bits that need to go in.
Group A carbon mirrors Jobs to do to Finish
Brake lines through car
Install perspex windows
Install wiring loom and cut down
Install fire extinguisher and cut off
Find omega gear box and prop
Iv started installing the loom today
, which if you read my posts from above will know that i didn't mark any thing up. However i did sort of remember where every thing went so wasn't to bad.
As the car doesn't need the electric windows , mirrors, heater, abs, clocks, check computer etc from before , iv also started to unrap the loom and cut the bits out that aren't required. Following the Bently wiring diagrams is great fun
Heres what i have cut out already
Thats the progress on the loom so far.
Got my flocked dash back this week
Here is the compay that did the work,(they had some stunning mk1 and 2 escorts there)http://www.centralblastcleaning.co.uk/s ... ocking.php
The quality of the flocking is awesome and I'm over the moon with the results. Does any body know how durable the flocking is?
On the donor car front, iv been looking at every possible website for the right car but nothing yet.The Donor
Picked up the Saab 9000 aero this morning and paid just £650 for it.
The body is rough as a bears bottom (perfect) but the engine is mint and clearly had a bit of cash spent on it.including saab flight stage 3 ecu, dump valve, induction kit, silicon hoses, new radiator and electric fan with switch on dash, boost gauge, poly engine gearbox mounts etc etc
Also have a Dyno chart stating 304bhp and 320nm of torque. She felt chubby quick in the saab body which weighs 1438kg, so i think the 1000kg e30 will be great fun especially with the 50% locking lsd.
Heres a few pictures
And the important part
I'm planning on starting the stripp down tomorrow and on the search for an omega gear box